Really? 110 views and not a single reply? I is sad panda. 
If you want a guide before playing a KM/SD, come back in like a month.
Ok, in the hopes of getting this discussion rolling.
Well shield defence has two different levels of indestructible: softcapped defence, and softcapped defence debuff resistance. Without spending an insane amount you're looking at the former. The latter requires not only defence slotting but also significant amounts of global recharge and slotting Hami-Os in Active Defense.
Sizable positional defence set bonuses tend to be for the 5th or 6th slots making internal slotting of powers slightly inflexible.
Melee defence for example is available through 6 slotting melee attacks with Touch of Death. You are therefore a little stuck with the accuracy, recharge and endurance reduction that set provides and as the set only has ~43% accuracy slotting you may feel the need to slot remaining powers for bonus accuracy and/or to-hit; the Kismet unique in Phalanx Fighting might be good on a budget. Since the set does cap at 40 its supply is often less consistant, place reasonable bids as soon as you can afford them and wait to see if anyone sells them to you before you get to 37 and can start slotting.
Kinetic Melee has Focused Burst, 6 slotting Thunderstrikes in ranged attacks is a cheap, easy and rather effective way to gain ranged defence.
5 slotting Scirocco's Devish in Shield Charge and Burst gains a fair bit of AoE defence. skipping the damage proc and slotting a basic recharge in the 6th slot is ideal. 6 slotting Stamina with Performance Shifters also provides AoE defence as well as maximising recovery.
Blessing of the Zephyrs are still the best 'bang for slots' available, 3 slotting any travel powers you pick up is worth it for the ranged and AoE defence.
Gaussian's Fire Control 6 slotted gives defence to all 3 positions; while the recharge isn't optimal for power siphon the trade off is probably worth it.
Steadfast Protection Res/Def unique provides 3% defence to everything possible. I would actually recommend already having this slotted by level 12 if at all possible.
Defence powers themselves have few defence set bonuses and can be frankenslotted with collections of def/end IOs (with a def/end/rech making up for the expensive LoTG if necessary) to scavenge slots for other powers.
And so, a build attempt.
Villain Plan by Mids' Villain Designer 1.803
http://www.cohplanner.com/
Click this DataLink to open the build!
Level 50 Magic Brute
Primary Power Set: Kinetic Melee
Secondary Power Set: Shield Defense
Power Pool: Fitness
Power Pool: Fighting
Power Pool: Speed
Power Pool: Leaping
Ancillary Pool: Soul Mastery
Villain Profile:
Level 1: Body Blow -- T'Death-Acc/Dmg(A), T'Death-Dmg/EndRdx(3), T'Death-Dmg/Rchg(3), T'Death-Acc/Dmg/EndRdx(5), T'Death-Dmg/EndRdx/Rchg(5), T'Death-Dam%(7)
Level 1: Deflection -- RedFtn-Def/EndRdx(A), RedFtn-Def/EndRdx/Rchg(7), GftotA-Def/EndRdx(9), S'dpty-Def/EndRdx(13)
Level 2: Battle Agility -- RedFtn-Def/EndRdx(A), RedFtn-Def/EndRdx/Rchg(9), GftotA-Def/EndRdx(11), S'dpty-Def/EndRdx(11)
Level 4: Smashing Blow -- T'Death-Acc/Dmg(A), T'Death-Dmg/EndRdx(13), T'Death-Dmg/Rchg(15), T'Death-Acc/Dmg/EndRdx(15), T'Death-Dmg/EndRdx/Rchg(17), T'Death-Dam%(17)
Level 6: Power Siphon -- GSFC-ToHit(A), GSFC-ToHit/Rchg(19), GSFC-ToHit/Rchg/EndRdx(19), GSFC-Rchg/EndRdx(21), GSFC-ToHit/EndRdx(21), GSFC-Build%(23)
Level 8: True Grit -- Heal-I(A)
Level 10: Active Defense -- RechRdx-I(A), RechRdx-I(29)
Level 12: Hurdle -- Jump-I(A)
Level 14: Health -- Heal-I(A)
Level 16: Against All Odds -- EndRdx-I(A), EndRdx-I(31)
Level 18: Burst -- Oblit-Dmg(A), Oblit-Acc/Rchg(23), Oblit-Dmg/Rchg(25), Oblit-Acc/Dmg/Rchg(25), Oblit-Acc/Dmg/EndRdx/Rchg(27)
Level 20: Stamina -- P'Shift-EndMod(A), P'Shift-EndMod/Rchg(31), P'Shift-EndMod/Acc/Rchg(31), P'Shift-Acc/Rchg(33), P'Shift-EndMod/Acc(33), P'Shift-End%(33)
Level 22: Boxing -- Empty(A)
Level 24: Tough -- S'fstPrt-ResDam/Def+(A)
Level 26: Focused Burst -- Thundr-Acc/Dmg(A), Thundr-Dmg/EndRdx/Rchg(27), Thundr-Acc/Dmg/EndRdx(29), Thundr-Dmg/Rchg(36), Thundr-Dmg/EndRdx(37), Thundr-Acc/Dmg/Rchg(37)
Level 28: Weave -- RedFtn-Def/EndRdx(A), RedFtn-Def/EndRdx/Rchg(36), GftotA-Def/EndRdx(39), S'dpty-Def/EndRdx(39)
Level 30: Phalanx Fighting -- Ksmt-ToHit+(A)
Level 32: Concentrated Strike -- T'Death-Acc/Dmg(A), T'Death-Dmg/EndRdx(34), T'Death-Acc/Dmg/EndRdx(34), T'Death-Dmg/Rchg(34), T'Death-Dmg/EndRdx/Rchg(36), T'Death-Dam%(40)
Level 35: Shield Charge -- Sciroc-Acc/Dmg(A), Sciroc-Dmg/Rchg(37), Sciroc-Acc/Rchg(39), Sciroc-Acc/Dmg/EndRdx(40), Sciroc-Dmg/EndRdx(43), RechRdx-I(43)
Level 38: Hasten -- RechRdx-I(A), RechRdx-I(40)
Level 41: Gloom -- Thundr-Acc/Dmg(A), Thundr-Dmg/EndRdx(42), Thundr-Dmg/Rchg(42), Thundr-Acc/Dmg/Rchg(42), Thundr-Dmg/EndRdx/Rchg(43), Thundr-Acc/Dmg/EndRdx(45)
Level 44: Dark Obliteration -- Posi-Acc/Dmg(A), Posi-Dmg/EndRdx(45), Posi-Acc/Dmg/EndRdx(45), Posi-Dmg/Rchg(46), Posi-Dmg/Rng(46), RechRdx-I(46)
Level 47: Combat Jumping -- Zephyr-Travel(A), Zephyr-Travel/EndRdx(48), Zephyr-ResKB(48), DefBuff-I(48), DefBuff-I(50)
Level 49: Super Speed -- Zephyr-Travel(A), Zephyr-Travel/EndRdx(50), Zephyr-ResKB(50)
------------
Level 1: Brawl -- Empty(A)
Level 1: Sprint -- ULeap-Stlth(A)
Level 2: Rest -- Heal-I(A)
Level 1: Fury
Level 1: Ninja Run
Softcapped to all 3 positions, no purples, no pvp stuff.
Should be capable of running Body Blow->Smashing Blow->Focused Burst->Gloom->Body Blow->Smashing Blow->Focused Burst->Body Blow->Gloom->Concentrated Strike with no gaps. 159 DPS at 70% fury with no procs or power siphon taken into account and 1 foe in AAO.
So, I'm dead set on this combo, having done some research and played it to 12 thus far. However, I'm completely new to Shield Defense and, of course, Kinetic Melee is a new animal altogether. Sure, there are Elec/Shield and SS/Shield guides, but I feel that it's not always ideal to cherry pick ideas from a build written from a different perspective. Certain sets synergize better. What I'm looking for is an IO build, as I'm completely unfamiliar with IO sets for the most part. How can I become the most indestructible Shield Brute I can be without spending an insane amount of inf?
Also, what *is* considered an insane amount? What is generally accepted as "affordable?" 50M? 100M? 1B? I have no idea. In addition, when is the ideal time to start slotting sets? Thus far, I've always used DOs for 12-22 and slotted generic IOs at 22 and up, not getting into sets until 40+. Reason being, I figure sets are something you don't want to ever replace, so don't slot them at low levels where they'll be outperformed. (Like a lvl 25 Mako's Bite Acc/Dam giving +20% where a lvl 50 Mako's Bite Acc/Dam gives +40%)
Any and all help/advice is appreciated. Thanks in advance!